Methods and systems for abrasive cleaning and barrier coating/sealing of pipes

ABSTRACT

Methods for abrasive cleaning, deburring, providing barrier coatings and sealing leaks in existing pipes, in a single operation, in one pass by intermittent bursts of dry particulates forced and pulled by air throughout the piping system by a generator and a vacuum. Cleaning includes intermittently injecting bursts of abrasive particles into the pressurized gas into the piping system for cleaning pipe interior walls, reducing burrs and interior lips in the pipe interior walls and generating a vacuum suction in the piping system to remove abrasive particles and debris.

This invention is a Continuation-In-Part of U.S. patent application Ser.No. 11/246,825 filed Oct. 7, 2005 now U.S. Pat. No. 7,517,409, which isa Divisional of U.S. patent application Ser. No. 10/649,288 filed Aug.27, 2003, now issued as U.S. Pat. No. 7,160,574 on Jan. 9, 2007, whichclaims the benefit of priority to U.S. Provisional Patent Application60/406,602 filed Aug. 28, 2002.

FIELD OF INVENTION

This invention relates to renovating of the interiors of pipes, and inparticular to methods, systems and apparatus for abrasive cleaning andproviding protective barrier coatings in a single operation to theinterior walls of small diameter metal, PEX type, CPVC and plastic typepressurized pipes such as pressurized drain lines, hot water lines, coldwater lines, potable water lines, natural gas lines, HVAC pipingsystems, fire sprinkler system lines, and the like, that are used inmulti-unit residential buildings, office buildings, commercialbuildings, and single family homes and the like.

BACKGROUND AND PRIOR ART

Over time building piping systems such as those used in commercialbuildings, apartment buildings, condominiums, residential homes and thelike, that have a broad base of users commonly develop problems with thebuilding pipes such as with their water and plumbing pipes, and thelike. Presently when a failure in a piping system, such as a leak occursthe repair method can involve a number of separate repair applications.Those repair applications often involve a specific repair to the area offailure such as replacing that section of pipe or the use of a clampingdevise and a gasket. However, these popular types of repair applicationscan cause additional problems with the building piping system.

Problems such as low water flow, or discolored water can result frombuild-up of materials, and the like occurring inside the pipe that hasnot been properly cleaned. Additional problems associated withinstalling a cut pipe that has not been reamed or deburred can causewater turbulence as the water flows over an unreamed burr or lip leftinside the pipe. Such problem can be a prime cause of erosion corrosioninside the pipes which quickens the deterioration and lifespan of thepipes.

Traditional techniques to correct for a potential leak, an actual leak,buildup or blockage or reducing or removing an unreamed lip or burr haveincluded replacing some or all of a building's pipes. In addition to thelarge expense for the cost of the new pipes, additional problems withreplacing the pipes can include the immense labor and construction coststhat must be incurred for these projects. In addition the down time tothe piping systems undergoing the repairs adds extra expense anddiscomfort to those needing to use the piping systems.

There are additional complications since most piping systems are locatedbehind finished walls or ceilings, under floors, in concrete orunderground. From a practical viewpoint simply getting to the problemarea of the pipe to make the repair can create the largest problem.Reaching to the pipe for making repairs can require tearing up thebuilding, cutting concrete and/or having to dig holes through floors,the foundation or the ground. These labor intensive repair projects caninclude substantial demolition of a buildings walls and floors in orderto access the existing piping systems. For example, tearing out of theinterior walls to access the pipes is an expected result of thedemolition necessary to fix existing pipes.

Additionally, there are usually substantial time-consuming costs forremoving the debris and old pipes from the worksite. With these projectsboth the cost of new pipes, the ancillary repair to the building and theadditional labor to install these pipes require expensive and timeconsuming expenditures. Further, there are additional added costs forthe materials and labor to replumb these new pipes along with thenecessary wall and floor repairs that must be made after the repairs toclean up for the demolition effects.

Under current repair applications, just reaching at and fixing a pipebehind drywall is not completing the repair project. The drywall or wallcovering surfaces must also be repaired, and just these types of repairscan be extremely costly. Additional expenses related to the repair orreplacement of an existing piping system will vary depending primarilyon the location of the pipe, the building finishes surrounding the pipeand the presence of hazardous materials such as asbestos encapsulatingthe pipe. Furthermore, techniques for making piping repair takeconsiderable amounts of time which results in lost use and lost revenuefrom tenants and occupants of commercial type buildings since tenantscannot use the buildings until the repairs are done.

Finally, the current pipe repair techniques are usually only temporary.Even after encountering the cost to repair the pipe, the cost andinconvenience of tearing up walls or grounds and if a revenue propertythe lost revenue associated with the repair or replacement, the repairedand/or new pipe(s) will still be subject to the corrosive effects ofwater type fluids that flow through the pipes.

Governments and municipalities are now beginning to recognize and dealwith corrosive effects of metal building piping systems. On Sep. 30,2005, the State of California recognizing the negative effects ofcorrosive water on metallic piping systems signed into law Assembly Bill1953, which reduces the allowable amount of lead in potable waterdelivery systems (such as through metal pipes) to 0.25%. The billstates: “No person shall introduce into commerce, for use in California,any pipe, pipe or plumbing fitting, or fixture intended to convey ordispense water for human consumption through drinking water or cookingthat is not lead free, as defined in subdivision (e). This includeskitchen faucets, bathroom faucets, and any other end-use devicesintended to convey or dispense water for human consumption throughdrinking or cooking.”

Over the years many different attempts and techniques have been proposedfor cleaning water type pipes with chemical cleaning solutions. See forexample, U.S. Pat. No. 5,045,352 to Mueller; U.S. Pat. No. 5,800,629 toLudwig et al.; U.S. Pat. No. 5,915,395 to Smith; and U.S. Pat. No.6,345,632 to Ludwig et al. However, these systems generally require theuse of chemical solutions such as liquid acids, chlorine, and the like,that must be run through the pipes as a prerequisite prior to anycoating of the pipes.

Other systems have been proposed that use dry particulate materials as acleaning agent that is sprayed from mobile devices that travel throughor around the pipes. See for example, U.S. Pat. No. 4,314,427 to Stolz;and U.S. Pat. No. 5,085,016 to Rose. However, these traveling devicesgenerally require large diameter pipes to be operational and cannot beused inside of pipes that are less than approximately 4 inches indiameter, and would not be able to travel around narrow bends. Thus,these devices cannot be used in small diameter pipes under 2 inches indiameter that also have sharp and narrow bends.

In some cases, compressed air carrying particles of abrasive material isblown through the pipe. Such a method is described, for example, in U.S.Pat. No. 5,622,209 to Naf and in U.S. Pat. No. 5,007,461 to Naf. In theNaf U.S. Pat. No. 5,007,461 the abrasive cleaning method describedinvolved the use of compressed air alone with a continuous feed ofabrasive material. And in the U.S. Pat. No. 5,622,209 to Naf, theinterior of the pipe is subsequently coated with an adhesive resin, suchas an epoxy resin, which is also applied by use of compressed air toblow it through the pipe.

The Naf patents described continuously blowing, large amounts of sand(approximately 200 Kg) that required extensive amounts air volume andpressure. Pre-drying took approximately 30 minutes, and a specialseparator was installed at the conduit outlet; the fine solid materialexiting (apparently mainly calcium deposits and rust) entered a specialseparator. Then a feeding device for the abrasive medium (dry regularsand with a grain size of 2 to 4 mm) was installed in the conduitbetween the compressor and the air inlet. A separator with a cycloneseparator with pressure gauge and regulating valve was installed at theair outlet. Then work was done for approximately 8 minutes at a meanoverpressure of approximately 1 atmosphere at highest compressor outputand greatest abrasive medium feed. At the end of blowing approximately200 kg of abrasive medium had been blown through the conduit to becleaned. At the end of blowing, the air exiting at the separator had atemperature of −50.degree. C. These elaborate blowing processes usinggreat amounts of abrasive material are prone to problems.

These processes of using compressed air in this way can only be used onrelatively small diameter pipes, and this cleaning technique easilyresults in blocking of the pipe, or major leaks in the pipe whenweakened after cleaning by constant high pressure and large amounts ofabrasive material being used. Also, the pipes are often not beadequately cleaned by such a processes when major frictional resistanceoccurs in the pipe system.

U.S. Pat. No. 5,924,913 of Reimelt attempts to overcome these problemsby using a suction at one end of a section of pipe. Reimelt specificallydiscusses the problems with NOT wanting to use compressed air suppliesfor renovating pipes since they result in damage to the interior of thepipes, blockages in the pipes and result in pollution. See column 2,lines 39-62. However, the Reimelt technique of only using a suction (lowpressure) at one end of a pipe section can also result in blockages andother problems. When an abrasive agent is repeatedly moved back andforth, it will gradually become mixed with the debris removed from thepipe surface, diluting or reducing the cleaning effect. Additionally,the Reimelt techniques require the use of heating devices such as wiresthat must be pulled or towed through pipe sections which adds additionalexpense and can also result in the dragged heating device damaging theinterior of the pipes or even getting stuck in the pipes. Also, theReimelt technique cannot be used with cleaning entire piping systemshaving bends and t-branches cannot be cleaned unless every pipe sectionis potentially taking apart and separately cleaned. Also, Reimelt cannotbe used with small pipes that need to be cleaned since the suction andheating devices cannot easily pass through pipes smaller thanapproximately 2½ inches in diameter.

Thus, the need exists for solutions to the above problems whereproviding a processes of abrasive cleaning in small diameter pressurizedpipes, up to 2 inches in diameter, that can be deburred, cleanedeffectively and efficiently, in-place, without clogging the pipe duringthe cleaning process, with minimal damage to the pipe and without largequantities of abrasive material being used. A further application of abarrier coating and sealing leaks is accomplished in piping systems in asingle operation, further protecting the piping system and all it'scomponents from the effects of corrosion, thereby reducing the leachingof heavy metals such as lead into the water supply.

SUMMARY OF THE INVENTION

A primary objective of the invention is to provide methods, systems anddevices for abrasive cleaning and preparation to the interior walls ofthe pipe and providing a protective barrier coating of pressurized pipesin buildings without having to physically remove and replace the pipes,where the pipes are cleaned, deburred, leaks sealed and the barriercoating is applied in a single operation.

A secondary objective of the invention is to provide methods, systemsand devices for abrasive cleaning and repairing interior walls andsealing leaks, in a single operation in pipes by initially cleaning theinterior walls of the pipes.

A third objective of the invention is to provide methods, systems anddevices for abrasive cleaning and repairing interior walls and sealingleaks, in a single operation in pipes by applying a corrosion protectionbarrier coating to the interior walls of the pipes that provides abarrier coating and seals leaks in one operation.

A fourth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaks,by applying a corrosion protection barrier coating to the interior wallsof the pipes in a single operation, in pipes in buildings in a costeffective and efficient manner.

A fifth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaks,by applying a corrosion protection barrier coating to the interior wallsof the pipes in a single operation, in pipes which is applicable tosmall diameter piping systems up to approximately 2 inches in diameterin piping systems made of various materials such as galvanized steel,black steel, lead, brass, copper or other materials such asCPVC(Chlorinated Polyvinyl Chloride) type, PVC (polyvinyl chloride)type, PEX (cross-linked polyethylene) type and composites includingplastics, as an alternative to pipe replacement or repair.

A sixth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation which is applied topipes, “in place” or insitu minimizing the need for opening up walls,floors ceilings, or grounds.

A seventh objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation, which minimizes thedisturbance of asbestos lined piping or walls/ceilings that can alsocontain lead based paint or other harmful materials.

An eighth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation, where once theexisting piping system is restored with a durable epoxy barrier coatingthe common effects of corrosion from water passing through the pipeswill be substantially delayed if not stopped entirely.

A ninth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation, to clean out blockagewhere once the existing piping system is restored, users will experiencean increase in the flow of water, which reduces the energy cost totransport the water. Additionally, the barrier epoxy coating leaksealant being applied to the interior walls of the pipes can createenhanced hydraulic capabilities again giving greater flow of water withreduced energy costs.

A tenth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation, where customersbenefit from savings in time associated with restoration of an existingpiping system.

An eleventh objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, where customersbenefit from the economical savings associated with the restoration andin-place leak repair of an existing piping system, since walls,ceilings, floors, and/or grounds would not need to be broken and/or cutthrough.

A twelfth objective of the invention is to provide methods, systems anddevices for abrasive cleaning, repairing interior walls, sealing leaksin pipes, by applying a corrosion protection barrier coating to theinterior walls of the pipes in a single operation, where incomeproducing commercial properties experience savings by remainingcommercially usable, and any operational interference and interruptionof commercial income-producing activities is minimized.

A thirteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, where healthbenefits accrue, as the water to metal contact will be stopped by abarrier coating thereby preventing the leaching of metallic andpotentially other harmful products from the pipe into the water supplysuch as but not limited to lead from solder joints and from lead pipes,and any excess leaching of copper, iron and lead.

A fourteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation where the pipesare being restored and repaired, in-place, thus causing less demand fornew metallic pipes, which is a non-renewable resource.

A fifteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, using a lessintrusive method of repair where there is less building waste and areduced demand on expensive landfills.

A sixteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, where the processuses specially filtered air that reduces possible impurities fromentering the piping system during the process.

A seventeenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, where theequipment package is able to function safely, cleanly, and efficientlyin high customer traffic areas.

An eighteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation where theequipment components are mobile and maneuverable inside buildings andwithin the parameters typically found in single-family homes, multi unitresidential buildings and various commercial buildings.

A nineteenth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation, where theequipment components can operate quietly, within the strictest of noiserequirements such as approximately seventy four decibels and below whenmeasured at a distance of approximately several feet away.

A twentieth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation where the barriercoating leak sealant material is applied to a variety of pipingenvironments, and operating parameters such as but not limited to a widetemperature range, at a wide variety of airflows and air pressures, andthe like.

A twenty first objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation where the barriercoating leak sealant material and the process is functionally able todeliver turnaround of restored piping systems to service withinapproximately twenty four hours or less.

A twenty second objective of the invention is to provide methods,systems and devices for abrasive cleaning, repairing interior walls,sealing leaks in pipes, by applying a corrosion protection barriercoating to the interior walls of the pipes in a single operation, wherethe barrier coating material is designed to operate safely under NSF(National Sanitation Foundation) Standard 61 criteria in domestic watersystems, with adhesion characteristics within piping systems in excessof approximately 400 PSI.

A twenty third objective of the invention is to provide methods, systemsand devices for abrasive cleaning, repairing interior walls, sealingleaks in pipes, by applying a corrosion protection barrier coating tothe interior walls of the pipes in a single operation where the barriercoating material is designed as a long-term, long-lasting, durablesolution to pipe corrosion, pipe erosion, pinhole leak repair andrelated water damage to piping systems where the barrier coating extendsthe life of the existing piping system.

A twenty fourth objective of the invention is to provide methods,systems and devices for both cleaning and coating interiors and leaksealing, the interior of pipes having diameters of up to approximately 2inches using dry particulates, such as sand and grit, prior to coatingthe interior pipe walls.

A twenty fifth objective of the invention is to provide methods, systemsand devices for abrasive cleaning, coating interiors and sealing leaksof pipes having diameters of up to approximately 2 inches, in or aroundbuildings, without having to section off small sections of piping forabrasive cleaning, coating and leak sealing applications.

A twenty sixth objective of the invention is to provide methods, systemsand devices for abrasive cleaning the interiors of an entire isolatedpiping system in a building in a single pass run operation.

A twenty seventh objective of the invention is to provide methods,systems and devices for applying a barrier coating and leak sealingcompound to the interiors of an entire isolated piping system in abuilding in a single pass run operation.

A twenty eighth objective of the invention is to provide methods,systems and devices for abrasive cleaning, of pipes having diameters ofapproximately ⅜ of an inch up to approximately 2 inches, in or aroundbuildings, without having to section off small sections of piping forabrasive cleaning, where the abrasive cleaning reduces or eliminates thelip or burr associated with unreamed pipe. i.e.: deburring installedpipe.

A twenty ninth objective of the invention is to provide methods, systemsand devices for abrasive cleaning the inside walls of piping systemshaving bends of up to approximately ninety degrees and branches, such ast-branches coming out from the pipes, using a compressed gas source atone end in combination with a vacuum generator at another end of thepiping system so that the entire system can be cleaned in a single passrun.

A thirteenth objective of the invention is to provide methods, systemsand devices for barrier coating and leak sealing the inside walls ofpiping systems having bends of up to approximately ninety degrees andbranches, such as t-branches coming out from the pipes, using acompressed gas source at one end in combination with a vacuum generatorat another end of the piping system so that the entire system can becleaned in a single pass run.

The novel method and system of abrasive cleaning during pipe restorationprepares small diameter piping systems such as those within the diameterrange of up to approximately 2 inches which can include straight andbent sections of piping and t-branches for the application of aprotective barrier coating leak sealant.

The novel method of abrasive cleaning and prepares the piping system forapplication of a barrier coating and leak repair, in a single operationand can be applied to potable water lines, natural gas lines, HVACpiping systems, hot water lines, cold water lines, pressurized drainlines, and fire sprinkler systems.

The novel method of abrasive cleaning allows for a method of abrasivecleaning in pressurized pipes up to 2 inches in diameter that reducesthe amount of abrasive material required, reduces the physical impactand damage to the interior pipe wall and reduces clogging of abrasivematerial and debris in the pipe, during the cleaning stage.

The novel method of abrasive cleaning allows for a method of abrasivecleaning in pressurized pipes up to 2 inches in diameter that reduces oreliminates the unreamed lip inside an unreamed or improperly reamedpipe.

The novel method of abrasive cleaning with the use of a vacuum airfilter reduces the effects of friction loss in small diameter pipes upto 2 inches, enhancing exiting of the abrasive material and debris andenhancing impact effectiveness of the abrasive material.

The novel use of the vacuum air filter used without the compressorenhances the drying of the pipe, during the pre cleaning drying stage,enhances the release of spent abrasive and debris during the cleaningstage and enhances the drying of the barrier coating, during the dryingstage.

The novel method of abrasive cleaning and application of an epoxybarrier coating leak sealant is applied to pipes right within the wallseliminating the traditional and expected destruction of the walls thatis usually associated with a re-piping job. Typically a piping system orsection of pipe can be isolated and the restoration of the system orsection of pipe can be completed in less than one to four days(depending upon the building size and type of application) with pipingfluid flow (such as water) restored within less than approximately 24 toapproximately 96 hours.

For most applications, there are no walls to cut, no large piles ofwaste, no dust and virtually no lost use of the building. Entirebuilding piping systems can be cleaned within one run through pass ofusing the invention. Likewise, an entire building piping system can becleaned, coated and leaks sealed within one single pass operation aswell.

Once cleaned, the applied epoxy coating not only seals the leak butcreates a barrier coating on the interior of the pipe in the sameoperation. The application process and the properties of the epoxycoating ensure the interior of the piping system is fully coated andleaks repaired.

Currently, there are primarily three types of metallic piping systemsthat are commonly used in the plumbing industry: copper, steel and castiron. New steel pipes are treated with various forms of barrier coatingsto prevent or slow the effects of corrosion.

A common barrier coating used on steel pipe is the application of a zincbased barrier coat commonly called galvanizing. New copper pipes usuallyhave no barrier coating protection. For years copper pipes were thoughtto be corrosion resistant offering a lifetime trouble free use as apiping system.

Under limited circumstances that involved a combination of factors ofwhich the chemistry of water and installation practices a naturaloccurring barrier coating could sometimes form on the inside of copperpipes which would act as a barrier coating, protecting the copper pipingsystem against the effects of corrosion from the water. However, inrecent history, due to changes in the way drinking water is beingtreated and changes in installation practices, these natural occurringbarrier coatings on the inside of copper pipes are not being formed orif it was formed it is now being washed away. In either case without anadequate natural occurring barrier coating, the copper pipe is exposedto the effects of corrosion/erosion, which can result in premature agingand failure of the piping system, most commonly referred to as a pinholeleak.

With galvanized pipe the zinc coating wears away leaving the pipeexposed to the effects of the corrosive activity of the water. Thisresults in the pipe rusting and eventually failing.

The invention can also be used with piping systems having plastic pipes,PEX (cross-linked polyethylene) type pipes, CPVC(Chlorinated PolyvinylChloride) type pipes, PVC (polyvinyl chloride) type pipes, compositematerial, and the like.

The novel method and system of abrasive cleaning and corrosion controlby the application of an epoxy barrier coating and sealant can beapplied to existing piping systems in-place, in the same operation.

The invention includes novel methods and equipment for abrasive cleaningand providing barrier coating corrosion and repair methods for sealingleaks for the interior walls of small diameter piping systems in thesame operation.

The novel process method and system of abrasive cleaning and internalleak repair and corrosion control includes at least three basic steps:Air Drying a piping system to be serviced; profiling the piping systemusing an abrasive cleaning agent; and applying the barrier coating leaksealant to selected coating thickness layers inside the pipes.

The novel invention can also include two additional preliminary stepsof: diagnosing problems with the piping system to be serviced, andplanning and setting up the barrier coating leak repairs project onsite.Finally, the novel invention can include a final end step of evaluatingthe system after applying the barrier coating leak repair andre-assembling the piping system.

A preferred method of cleaning out pipe systems, can include the stepsof generating pressurized gas into one end of a piping system havingpipes, intermittently injecting bursts of abrasive particles into thepressurized gas into the end of the piping system, cleaning interiorwall surfaces of the pipes with the intermittent bursts of the abrasiveparticles, reducing burrs, interior lips and excess seam joint edges inthe interior wall surfaces of the pipes, and generating a vacuum suctionat another end of the piping system to remove the abrasive particles anddebris caused by the cleaning of the interior walls of the pipes.

The pipes can be small pipes having diameters of approximately ⅜ of aninch to approximately 2 inches, and preferably diameters ofapproximately ⅜ of an inch to approximately 1¾ inches. The pipes can bemetal pipes such as copper pipes and steel pipes, as well as other typesof pipes such as but not limited to CPVC(Chlorinated Polyvinyl Chloride)type, PVC (polyvinyl chloride) type, PEX (cross-linked polyethylene)type and composites including plastics.

The intermittent bursts can include introducing a cumulative amountbetween approximately 0.15 kg to less than 5 kg of abrasive particulatesper a piping length of between approximately ⅓ m to approximately 100 m.

For pipes having diameters of between approximately ⅜ inch toapproximately 1 inch, the cumulative amount of the abrasive particlescan be between approximately 0.15 kg to less than approximately 3 kg.

For pipes having diameters of between approximately 1¼ inches toapproximately 1¾ inches, the cumulative amount of the abrasive particlescan be between approximately 0.5 kg to less than 5 kg.

For pipes having diameters of between approximately 1¾ inches toapproximately 2 inches, the cumulative amount of the abrasive particlescan be between approximately 0.5 kg to less than 5 kg.

The method can include cleaning the interior walls of the pipes whilethe pipes have a temperature of between approximately 25 C toapproximately 40 C.

For cleaning copper pipes, the abrasive particulates can be selectedfrom at least one of: Silica, Garnett and Aluminum Oxide, with Garnetand Aluminum Oxide are most preferable since Aluminum Oxide is hard andGarnet is readily available and is environmentally desirable. The meshsize for particulates for copper pipes can be a range between 12 to 45mesh sizes.

For cleaning steel pipes, the abrasive particles can be selected from atleast one of: Silica, Garnett, Silicon Carbide and Aluminum Oxide, withSilica, Silicon Carbide and Aluminum would be most preferable in view ofthe their hardness for steel pipes. The mesh size for particulates forsteel pipes can be a range between 12 to 60 mesh sizes.

With a piping diameter of approximately ½ inch, the air pressure can beapproximately 2 to approximately 6 bar, and the abrasive particulatesper shot are approximately 25 to approximately 80 grams.

With a piping diameter of approximately ¾ of an inch, the air pressurecan be approximately 2 to approximately 6 bar, and the abrasiveparticulates per shot are approximately 40 to approximately 120 grams.

With a piping diameter of approximately 1 inch, the air pressuregenerated can be approximately 2 to approximately 6 bar, and theabrasive particulates per shot are approximately 60 to approximately 160grams.

With a piping diameter of approximately 1½ of an inch, the air pressuregenerated can be approximately 3 to approximately 7 bar, and theabrasive particulates per shot are approximately 75 to approximately 200grams.

With a piping diameter of approximately 1¾ of an inch, the air pressuregenerated can be approximately 3 to approximately 7 bar, and theabrasive particulates per shot are approximately 75 to approximately 200grams.

The novel method can also include the steps of coating the interiorwalls of the cleaned piping system with a barrier coating leak sealantwith the compressed air source and the vacuum source attached to thepiping system.

A preferred system of cleaning out building pipe systems having pipeswith bends of approximately 90 degrees and t-branches would include agenerator for generating pressurized/compressed gas into one end of apiping system, a source for intermittently injecting bursts of abrasiveparticles into the pressurized gas and into the end of the pipingsystem, the intermittent bursts for cleaning interior wall surfaces ofthe pipes and reducing burrs, interior lips and excess seam joint edgesin the interior wall surfaces of the pipes, and a vacuum source forgenerating a vacuum suction at another end of the piping system toremove the abrasive particles and debris caused by the cleaning of theinterior walls of the pipes. Another source can be added for coating theinterior walls of the cleaned pipes with a barrier coating using thepressurized/compressed gas generator and vacuum source.

Further objects and advantages of this invention will be apparent fromthe following detailed description of the presently preferredembodiments which are illustrated schematically in the accompanyingdrawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the general six steps that is an overview for profiling andabrasively cleaning interior walls of pipes and applying the barriercoating leak sealant to the walls.

FIGS. 2A, 2B, 2C and 2D shows a detailed process flowchart using thesteps of FIG. 1 for providing the abrasive cleaning and applying thebarrier coating leak sealant.

FIG. 3 shows a flow chart of the set up of the invention.

FIG. 4 shows an illustration of the effects of deburring and waterturbulence, before and after the cleaning and coating process is used.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining the disclosed embodiments of the present invention indetail it is to be understood that the invention is not limited in itsapplication to the details of the particular arrangements shown sincethe invention is capable of other embodiments. Also, the terminologyused herein is for the purpose of description and not of limitation.

This invention is a Continuation-In-Part of U.S. patent application Ser.No. 11/246,825 filed Oct. 7, 2005, which is a Divisional of U.S. patentapplication Ser. No. 10/649,288 filed Aug. 27, 2003, now issued as U.S.Pat. No. 7,160,574 on Jan. 9, 2007, which claims the benefit of priorityto U.S. Provisional Patent Application 60/406,602 filed Aug. 28, 2002,all of which are assigned to the same assignee as the subject inventionand all of which are incorporated by reference.

FIG. 1 shows the general six steps for a project overview for applyingthe barrier coating leak sealant to an existing piping system, whichinclude step one, 10 program diagnosis, step two, 20 project planning,step three, 30 drying piping system, step four 40, profiling anddeburring the piping system, step five, 50 applying barrier coating leaksealant to the interior walls of the pipes in the piping system, andfinal step six 60 evaluation and return to operation of the pipingsystem.

Step One—Problem Diagnosis 10

For step one, 10, several steps can be done to diagnose the problem witha piping system in a building, and can include:

-   -   (a) Interview onsite engineering staff, property managers,        owners or other property representatives as to the nature of the        current problem with the piping system.    -   (b) Evaluation of local and on-site water chemistry being used        in the piping system for hardness and aggressive qualities.    -   (c) Engineering evaluation, if necessary, to determine extent of        present damage to the wall thickness of the piping and overall        integrity of the piping system.    -   (d) Additional on-site testing of piping system, if necessary,        identifying leaks or the nature or extent of leaking.    -   (e) Corrosion control, leak sealing proposal development for        client, including options for pipe and fitting replacement where        necessary.    -   After completion of step one, 10, the project planning and setup        step 20 can be started.        Step Two—Project Planning and Setup 20

For step two, 20, several steps can be followed for planning and setupfor restoring the integrity of the piping system in a building, and caninclude:

-   -   (a) Complete contract development with client, after the        diagnosis contract has started.    -   (b) Commence project planning with site analysis crew, project        management team, and on-site engineering/maintenance staff.    -   (c) Plan delivery of the equipment and supplies to the worksite.    -   (d) Complete equipment and supply delivery to worksite.    -   (e) Commence and complete mechanical isolation of the piping        system.    -   (f) Commence and complete set up of hosing and equipment.        Step Three—Air Drying—Step 1 Method of Corrosion Control and        Leak Repair 30

For step three, 30, the piping system to be prepared for the coating bydrying the existing pipes, and can include:

-   -   (a) Piping systems are mapped.    -   (b) Isolation of piping systems or pipe sections are prepared        and completed.    -   (c) The isolated piping system to receive the barrier coating        leak sealant is adapted to be connected to the barrier coating        equipment.    -   (d) The isolated pipe section or system is drained of water.    -   (e) Using moisture and oil free, hot compressed air, a flushing        sequence is completed on the piping system to assure water is        removed.    -   (f) Piping system is then dried with heated, moisture and oil        free compressed air. The piping system is heated in the        approximate range of approximately 25 to approximately 40        degrees Celsius    -   (g) Length of drying sequence is determined by pipe type,        diameter, length complexity, location and degree of corrosion        contained within the piping system, if any.    -   (h) Exiting debris is captured with use of an air filter vacuum,        drawing air, which can be used simultaneously with the        compressor.    -   (i) Inspections are completed to assure a dry piping system        ready for the barrier coating and sealant.        Step Four—Piping System Profiling—Step 2 of Method of Corrosion        Control and Leak Sealant 40

For step four, 40, the piping system is to be profiled, and can include:

-   -   (a) Dried pipes can be profiled using an abrasive agent in        varying quantities and types. The abrasive medium can be        introduced into the piping system by the use of the moisture and        oil free heated compressed air using varying quantities of air        and varying air pressures. The amount of the abrading agent is        controlled by the use of a pressure generator. The abrading        agent is introduced into the air stream using a burst technique        wherein small amounts of the abrasive are introduced into the        air stream, travel through the pipe and exit, wherein the next        amount or shot of abrasive is introduced.    -   (b) The simultaneous use of the air filter vacuum at the exit        end, drawing air to assist the compressor, reducing the effects        of friction loss in the piping system, enhancing the effects of        the sanding and debris removal.    -   (c) The abraded pipe, when viewed without magnification, must be        generally free of all visible oil, grease, dirt, mill scale, and        rust. Generally, evenly dispersed, very light shadows, streaks,        and discolorations caused by stains of mill scale, rust and old        coatings can remain on no more than approximately 33 percent of        the surface. Also, slight residues of rust and old coatings can        be left in the craters of pits if the original surface is        pitted.    -   (d) Pipe profiling is completed to ready the pipe for the        application of the barrier coating leak sealant material.    -   (e) Visual inspections can be made at connection points and        other random access areas of the piping system to assure proper        cleaning and profiling standards are achieved.    -   (f) An air flushing sequence is completed to the piping system        to remove any residuals left in the piping system from the        profiling stage.        Step Five—Corrosion Control Epoxy Sealing Leak Repair and        Protection of the Piping—Step 3 of the Method of Corrosion        Control and Leak Repair 50

For step five, 50, the piping system is protected with a barrier coatingand leaks sealed and can include:

-   -   (a) Piping system can be heated with hot, pre-filtered, moisture        and oil free compressed air to an appropriate standard for an        epoxy coating application. Pipes can be heated to approximately        25 to approximately 40 degrees Celsius    -   (b) Piping system can be checked for leaks.    -   (c) If leaks are identified or are suspect and the approximate        size determined the operator can choose to apply the coating        material without fillers, if the leak is determined to        be >approximately 30 mils in width the operator can decide to        add fillers to the coating material, prior to injection into the        piping system.    -   (d) Coating and leak sealing material can be prepared and        metered to manufacturer's specifications using a proportionator.    -   (e) The barrier coating leak sealant and fillers are placed into        the epoxy carrying tube or injection device.    -   (f) The coating and leak sealant material can be injected into        the piping system using hot, pre-filtered, moisture and oil free        compressed air at temperatures, air volume and pressure levels        to distribute the epoxy barrier coating leak sealant throughout        the pipe segment, in sufficient amounts to eliminate the water        to pipe contact in order to create an epoxy barrier coating on        the inside of the pipe and seal the leak in a single operation.        During this wetting out stage a vacuum filter can be used in        conjunction with the compressor to assist the wetting out of the        coating material. At all times, a neutral or positive pressure        must be maintained on the inside of the pipe.    -   (g) The coating can be applied to achieve a coating of at least        approximately 4 mils and sealing leaks up to approximately 125        mils in size.    -   (h) Once the epoxy barrier coating leak sealant is injected and        the piping segment is wetted out warm, pre-filtered, moisture        and oil free compressed air can be applied to create a positive        pressure inside the pipe with a continuous positive pressure        maintained of at least approximately 1.5 P.S.I. over the        internal surface of the pipe to achieve the initial set of the        epoxy barrier coating sealant takes place. After initial set and        still maintaining positive pressure confirm that all valves and        pipe segments support appropriate air flow indicating clear        passage of the air through the pipe i.e.: no areas of blockage.        Allow the barrier coating leak sealant to cure to manufacturer's        standards.        Step Six—System Evaluation and Re-Assembly 60

The final step six, 60 allows for restoring the piping system tooperation and can include:

-   -   (a) Remove all process application fittings.    -   (b) Examine pipe segments to assure appropriate coating        standards, checks to ensure all leaks are sealed.    -   (c) Re-confirm that all valves and pipe segments support        appropriate air flow.    -   (d) Install original valves, fittings/fixtures, or any other        fittings/fixtures as specified by building owner representative.    -   (e) Reconnect water system, and water supply.    -   (f) Complete system checks, testing and evaluation of the        integrity of the piping system.    -   (g) Complete a water flush of system, according to        manufacturer's specifications.    -   (h) Evaluate water flow and quality.    -   (i) Document piping layout schedule, and complete pipe labeling.

FIGS. 2A, 2B, 2C and 2D show a detailed process flowchart using thesteps of FIG. 1 for cleaning the interior walls of the pipes and forproviding the barrier coating leak sealant. These flow chart figuresshow a preferred method of applying a novel barrier coating leak sealantfor the interior of small diameter piping systems following a specificbreakdown of a preferred application of the invention.

Components in FIG. 3 will now be identified as follows:

IDENTIFIER EQUIPMENT 100 Compressors Outfitted with Aftercooler, Waterseparator, Fine Filter and Reheater (if required) 200 Main Air Headerand Distributor (Main Header) 300 Floor (Mini) Manifold (optional) 400Sander 500 Pre-Filter 600 Dust Collector System (Air Filter Vacuum) 700Portable Epoxy Metering and Dispensing Unit (Epoxy Mixer) 800 EpoxyBarrier Coating and Sealant 900 Epoxy Carrying Tube - Injection Device

Referring to FIG. 3, components 100-900 can be located and used atdifferent locations in or around a building. The invention allows for anentire isolated building piping system to be cleaned in one single passthrough run without having to dismantle either the entire or multiplesections of the piping system. The piping system can include pipeshaving diameters of up to approximately 2 inches in diameter with thepiping including bends up to approximately ninety degrees or morethroughout the building and include at t-branches in the piping systems.The invention allows for an entire isolated building piping system tohave the interior surfaces of the pipes cleaned, coated and leaks sealedin one single pass through run without having to dismantle either theentire or multiple parts of the piping system. Each of the componentswill now be defined.

100 Air Compressor

The air compressors 100 can provide filtered and heated compressed air.The filtered and heated compressed air employed in various quantities isused, to dry the interior of the piping system, as the propellant todrive the abrasive material used in cleaning of the piping system and isused as the propellant in the application of the epoxy barrier coatingleak sealant and the drying of the epoxy barrier coating leak sealantonce it has been applied. The compressors 100 also provide compressedair used to propel ancillary air driven equipment.

200 Main Air Header and Distributor

A main header and distributor 200 referred to in FIG. 3 can be oneManufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo StreetBrea, Calif. 92821.

The Main Header 200 provides safe air management capability from the aircompressor for both regulated and unregulated air distribution (or anycombination thereof) to the various other equipment components and toboth the piping system risers and fixture outlets for a range of pipingconfigurations in residential and/or commercial buildings that can rangefrom a single family home to a multi-story building.

300 Floor (Mini) Manifold

A floor or mini manifold 300 can be one Manufactured By: M & H Machinery45790 Airport Road, Chilliwack, BC, Canada

As part of the general air distribution system set up, the floormanifolds 300 can be pressure rated vessels designed to evenly andquietly distribute the compressed air to at least 5 other points ofconnection, typically being the connections to the piping system.Airflow from each connection at the manifold is controlled by the use ofindividual full port ball valves.

400 Pressure Generator System-Sander

A pressure generator sander 400 that can be used with the invention canbe one Manufactured By: Media Blast & Abrasives, Inc. 591 W. ApolloStreet Brea, Calif. 92821.

The pressure generating sander system 400 can provide easy loading andcontrolled dispensing of a wide variety of abrasive medium. The pressuregenerator sander can include operational controls that allow theoperator to easily control the amount of air pressure and control thequantity of the abrasive medium to be dispersed in a single or multipleapplication. The abrasive medium can be controlled in quantity and typeand is introduced into a moving air steam, using small bursts ofmaterial, that is connected to a pipe or piping systems that are to besand blasted clean by the abrasive medium. The abrasive medium can beintroduced by the pressure generator sander system 400 by beingconnected to and be located outside of the piping system depicted inFIG. 3. The novel application of the sander system 400 allows forcleaning small pipes having diameters up to approximately 2 inches.

Table 1 shows a list of preferred dry particulate materials with theirhardness ratings from 1 to 10 (being the hardest), and grain shapes thatcan be used with the sand generator 400, and Table 2 shows a list ofpreferred dry particulate particle sieve sizes that can be used with theinvention.

TABLE 1 PARTICULATES Material Moh Rating Grain Shape Silicon Carbide 10Cubical Aluminium Oxide 9 Cubical Silica 5 Rounded Garnet 5 Rounded

Table 1 shows the hardness and shapes of the typical types ofparticulates used in the cleaning and sanding process. Based on the Mohscale of hardness, it is found that a 5 or higher hardness particulatecan be used in this process. A particulate such as silicon carbide isrecommended over a softer garnet particulate when used to clean andprofile harder metal pipes, such as steel, where the metal is a softer,such as copper it can be cleaned and profiled with a less hardparticulate such as garnet.

Silica, Garnet and Aluminum Oxide can be used to clean copper,preferably Garnet and Aluminum Oxide are most preferable since AluminumOxide is hard and Garnet is readily available and is environmentallydesirable. The mesh size for particulates for copper pipes can be arange between 12 to 45 mesh sizes.

For cleaning steel pipes, Silica, Garnett, Silicon Carbide and AluminumOxide can be used. Preferably Silica, Silicon Carbide and Aluminum wouldbe most preferable in view of the their hardness for steel pipes. Themesh size for particulates for steel pipes can be a range between 12 to60 mesh sizes.

TABLE 2 PARTICULATE SIZE SIEVE SIZE OPENING U.S. Mesh Inches MicronsMillimeters 4 .187 4760 4.76 8 .0937 2380 2.41 16 .0469 1190 1.20 25.0280 710 .70 45 .0138 350 .35

Table 2 describes the various standards for measuring particulate size.In the cleaning and profiling stage an operator will decide to useparticulate of various sizes depending on the size of pipe, the type ofpiping material i.e. steel or copper and the degree and type of build upinside the pipe. In a copper pipe situation it is common to use a 24mesh size. When cleaning a heavily encrusted steel pipe an operatormight use a small particulate such as a 45 or 60 mesh to bore a holethrough the build up without getting clogged or plugged up inside thepipe. As the opening inside the pipe increases by the abrasive cleaning,larger particulate sizes can be used.

The following table 3 illustrates the approximate amount of pushing airvolume and pressure ranges required for adequate cleaning of pipes invarious diameters up to 2″ when used in conjunction with a vacuum assistat the exit.

TABLE 3 Pipe Size Air Volume Pressure Ranges (inches) (CFM) (bar) 0.5 801.5-7.0 0.75 80 1.00 80 1.25 125 1.50 175 1.75 225 2.00 275

The following Table 4 illustrates the amount of abrasive materialintroduced into a metal piping system in the form of a shot orintermittent bursts to adequately profile the pipe for the barriercoating. Note: the number of shots depends on pressure applied, actualconditions of the pipe, degree of any existing buildup inside the pipe,length of pipe, # of angles ie: bends, hardness and type and size ofabrasive. For this illustration the abrasive was aluminum oxide and thelength of pipe was 30 meters for 25 mesh.

TABLE 4 25 mesh ( .70 mm) Aluminum Oxide 9 Moh scale Pipe Size/type AirPressure Abrasive per shot # shots 0.5″ type/Cu 2-3 bar 25-80 grams 60.5″ type/galvanized 3-6 bar 25-80 grams 12-16 0.5″ type/CPVC, PEX 3-6bar 25-80 grams 12-16 0.75″ type/Cu 2-3 bar 40-120 grams 6 0.75″type/Galvanized 3-6 bar 40-120 grams 12-16 0.75″ type/CPVC, PEX 3-6 bar40-120 grams 12-16 1.00″ type/Cu 2-3 bar 60-160 grams 6 1.00″type/Galvanized 3-6 bar 60-160 grams 14-16 1.00″ type/CPVC, PEX 3-6 bar60-160 grams 14-16 1.5″ type/Cu 3-4 bar 75-200 grams 8 1.5″type/Galvanized 4-7 bar 75-200 grams 16-20 1.5″ type/CPVC, PEX 4-7 bar75-200 grams 16-20 1.75″ type/Cu 3-4 bar 75-200 grams 8 1.75″type/Galvanized 4-7 bar 75-200 grams 16-20 1.75″ type/CPVC, PEX 4-7 bar75-200 grams 16-20

Table 5 shows results for 16 mesh using Aluminum Oxide.

TABLE 5 16 mesh (1.20 m) Aluminum Oxide 9 Moh scale Pipe Size/type Airpressure Abrasive per shot # of shots 0.5″ type Cu 2-3 bar 25-80 grams 50.5″ type/Galvanized 3-6 bar 25-80 grams 10-12 0.5″ type/CPVC, PEX 3-6bar 25-80 grams 10-12 0.75″ type/Cu 2-3 bar 40-120 grams 5 0.75″type/Galvanized 3-6 bar 40-120 grams 10-12 0.75″ type/CPVC, PEX 3-6 bar40-120 grams 10-12 1.00″ type/Cu 2-3 bar 60-160 grams 5 1.00″type/Galvanized 3-6 bar 60-160 grams 14-16 1.00″ type/CPVC, PEX 3-6 bar60-160 grams 14-16 1.5″ type/Cu 3-4 bar 75-200 grams 8 1.5″type/Galvanized 4-7 bar 75-200 grams 16-20 1.5″ type/CPVC, PEX 4-7 bar75-200 grams 16-20 1.75″ type/Cu 3-4 bar 75-200 grams 8 1.75″type/Galvanized 4-7 bar 75-200 grams 16-20 1.75″ type/CPVC, PEX 4-7 bar75-200 grams 16-20

Table 6 shows 12 mesh with Aluminum Oxide.

TABLE 6 12 mesh (1.68 mm) Aluminum Oxide 9 Moh scale Pipe Size/type Airpressure Abrasive per shot # of shots 0.5″ type/Cu 2-3 bar 25-80 grams 50.5″ type/Galvanized 3-6 bar 25-80 grams 10-12 0.5″ type/CPVC,PEX 3-6bar 25-80 grams 10-12 0.75″ type/Cu 2-3 bar 40-120 grams 5 0.75″type/Galvanized 3-6 bar 40-120 grams 10-12 0.75″ type/CPVC, PEX 3-6 bar40-120 grams 10-12 1.00″ type/Cu 2-3 bar 60-160 grams 5 1.00″type/Galvanized 3-6 bar 60-160 grams 14-16 1.00″ type/CPVC, PEX 3-6 bar60-160 grams 14-16 1.5″ type/Cu 3-4 bar 75-200 grams 8 1.5″type/Galvanized 4-7 bar 75-200 grams 16-20 1.5″ type/CPVC, PEX 4-7 bar75-200 grams 16-20 1.75″ type/Cu 3-4 bar 75-200 grams 8 1.75″type/Galvanized 4-7 bar 75-200 grams 16-20 1.75″ type/CPVC, PEX 4-7 bar75-200 grams 16-20500 Abrasive Reclaim Separator Module (Pre-Filter)

A pre-filter that can be used with the invention can be one ManufacturedBy: Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, Calif.92821

During the pipe profiling stage, the Pre-Filter 500 allows the filteringof air and debris from the piping system. When used in conjunction withthe dust collection equipment 600, fine dust particles and air arecaptured and filtered

600 Dust Collection Filter—Air Filter Vacuum

An example of an air filter vacuum 600 used with the invention can beone Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street,Brea, Calif. 92821.

During the pipe profiling stage, the air filter vacuum or dust collector600 is the final stage of the air filtration process. The dust collector600 filters the passing air of fine dust and debris from the pipingsystem after the contaminated air first passes through the pre-filter500 (abrasive reclaim separator module).

During the drying stage the filter 600 can be used simultaneously withcompressor 100 which aids in drawing air through the piping system.During the sanding or cleaning stage the filter 600 can be used withcompressor 100 the filter 600 which assists by drawing air through thepiping system. The filter 600 can be used simultaneously with thecompressor 100 to create a pressure differential in the piping systemwhich is used to reduce the effects of friction loss and assists in apulling action within the pipe during the drying and sanding or cleaningstages as well as the coating stage.

700 Portable Epoxy Metering and Dispensing Unit

A metering and dispensing unit 700 used with the invention can be oneManufactured by: Lily Corporation, 240 South Broadway, Aurora, Ill.60505-4205.

The unit 700 can be very mobile and can be used both indoors andoutdoors. The unit 700 requires only a single operator.

The epoxy 800 can be metered to control the amount of epoxy beingdispensed.

800 Epoxy Barrier Coating Leak Sealant

A preferred epoxy barrier coating that can be used with the inventioncan be one Manufactured by: CJH, Inc. 2211 Navy Drive, Stockton, Calif.95206. The barrier coating product used in this process can be a 2-partthermo set resin with a base resin and a base-curing agent.

The preferred thermo set resin is mixed as a two-part epoxy that is usedin the invention. When mixed and applied, it forms a durable barriercoating leak sealant on pipe interior surfaces and other substrates. Thebarrier coating leak sealant provides a barrier coating that protectsthose coated surfaces from the effects caused by the corrosiveactivities associated with the chemistry of water and other reactivematerials on the metal and other substrates and seal leaks in the pipe.

The epoxy barrier coating sealant can be applied to create a protectivebarrier coating and leak sealant to pipes ranging in size up toapproximately 6″ and greater. The barrier coating can be applied aroundbends intersections, elbows, tees, to pipes having different diametersand make up. The barrier coating leak sealant can be applied to pipes inany position e.g.: vertical or horizontal and can be applied as aprotective coating leak sealant to metal and plastic type pipes used infire sprinkler systems and natural gas systems. At least anapproximately 4 mils coating layer can be formed on the interior wallsof the pipes. The barrier coating leak sealant protects the existinginterior walls and can also stop leaks in existing pipes which havesmall openings and cracks, and the like, of up to approximately 125 milsin size.

Although the process of application described in this invention includesapplication of thermo set resins other types of thermo set resins can beused.

For example, other thermo set resins can be applied in the process, andcan vary depending upon viscosity, conditions for application includingtemperature, diameter of pipe, length of pipe, type of material pipecomprised of, application conditions, potable and non potable watercarrying pipes, and based on other conditions and parameters of thepiping system being cleaned, coated and leaks sealed by the invention.

Other thermo set type resins that can be used include but are notlimited to and can be one of many that can be obtained by numeroussuppliers such as but not limited to: Dow Chemical, Huntsmans AdvancesMaterial, formerly Ciba Giegy and Resolution Polymers, formerly ShellChemical.

Fillers used in the process preferably can contain a mixture of low andhigh aspect ratio particles, acicular shaped particles, and plate likeparticles. The fillers can be inert material comprised of any one of thegroup of epoxy, glass, plastic foam parts, cork, clay.

Although the novel invention can be applied to all types of metal pipessuch as but not limited to copper pipes, steel pipes, galvanized pipes,and cast iron pipes, the invention can be applied to pipes made of othermaterials such as but not limited to plastics, PEX (cross-linkedpolyethylene) type pipes, CPVC(Chlorinated Polyvinyl Chloride) typepipes, PVC (polyvinyl chloride), composite materials, polybutidylene,and the like.

Additionally, small cracks and holes in plastic type and metal pipes canalso be fixed “in place” by the barrier coating leak sealant. A coatingof at least approximately 4 mils on the interior pipe walls, can be usedfor sealing leaks up to approximately 125 mils in size.

FIG. 4 shows an illustration of the effects of deburring and waterturbulence, before and after the cleaning and coating process is used.Before the cleaning process, water turbulence can be created by waterflowing against and over an unburred joint or excess solder at a joint,which can become further clogged and/or damaged as described above. Withthe subject invention cleaning operation, the burr or excess solder isreduced or eliminated in place, substantially improving water flow, flowof coating material and reducing effects of water turbulence, that caninclude excessive wear and damage. The abrasive technique in the subjectinvention greatly reduces or eliminates the lip(s) associated withundreamed or improperly reamed pipes.

Table 7 shows a comparison of prior art techniques (Japanese A-S MethodTable 4-3 and NAF U.S. Pat. No. 5,007,461) compared to the novel ACEmethod described in the subject invention.

TABLE 7 Amount of Abrasive Used A-S ACE Material Diameter Length MethodNAF Method Steel Pipe .5″-1″  10-20 m 5-10 kg .84-2.56 kg Steel Pipe1.25″-1.75″ 20-30 m 20-30 kg 1.2-4.0 kg Steel Pipe 1.00-1.5″ 70 m 200 kg1.2- 4.0 kg

The kg amounts are cumulative for the total amount of abrasive used.

In the subject invention, the unique combination of using small burstsof abrasive material combined with compressed air pushing and a vacuumpulling the material greatly improved the overall sanding performance.In the case of pipes having a diameter of 0.5″ to 1″ diameter, the same(similar) cleaning results were achieved using about 74 to about 83%less abrasive material. In the case of 1.25″ to 1.75″ diameter pipesapproximately 80 to approximately 92% efficiencies were noted.

In addition the push/pull method also reduced the overall impact on theinside walls of the piping system. The operator noted that they wereable to clean pipes using this method that had thinner side walls,resulting in less damage to the interior of the pipe when compared tothe conventional streaming of larger qualities of abrasive into the onedirectional pushing air stream.

The use of burst sanding in which the abrasive material is sent throughthe pipe in smaller quantities and is allowed to exit before introducingthe next burst makes the process more efficient, reduces the negativeeffects of simply adding a stream of material which in turn reduces theair flow and pressure inside the pipe which and reduces the impactassociated with the abrasive material striking the inside walls of thepipe. The vacuum assists by reducing friction loss in the run of thepipe, assist as well by drawing debris and the abrasive out of the pipe.

The prior art NAF used 1 Bar, and A-S Method used 2.5-3 kg/cm² or2.45-2.94 Bar. The subject invention's (ACE's) lower end of the scaleair pressures were within the average range when compared to the A-SMethod for respective pipe diameters i.e.: 3 bar on average, but thesubject invention (ACE) used a vacuum drawing air to assist.

Although the preferred applications for the invention are described withbuilding piping systems, the invention can have other applications suchas but not limited to include piping systems for swimming pools,underground pipes, in-slab piping systems, piping under driveways,various liquid transmission lines, tubes contained in heating andcooling units, tubing in radiators, radiant in floor heaters, chillersand heat exchange units, and the like.

While the invention has been described, disclosed, illustrated and shownin various terms of certain embodiments or modifications which it haspresumed in practice, the scope of the invention is not intended to be,nor should it be deemed to be, limited thereby and such othermodifications or embodiments as may be suggested by the teachings hereinare particularly reserved especially as they fall within the breadth andscope of the claims here appended.

We claim:
 1. A method of cleaning out pipe systems, comprising the stepsof: generating pressurized gas to form a moving air stream into one endof a piping system having pipes with piping diameters selected from thegroup consisting of approximately ½ inch, approximately ¼ of an inch,approximately 1 inch, approximately 1½ inch and approximately 1¾ inches;intermittently injecting bursts of abrasive particles in separate burstshots into the moving air stream at the one end of the piping system,and the abrasive particulates per shot having different range values foreach of the piping diameters; cleaning interior wall surfaces of thepipes with the separate burst shots of the abrasive particles; reducingat least one of burrs or interior lips in the interior wall surfaces ofthe pipes, with the separate burst shots of the abrasive particles thathave been intermittently injected into the moving air stream at the oneend of the piping system; and removing abrasive particles and debriscaused by each one of the separate burst shots of the abrasiveparticles.
 2. The method of claim 1, wherein at least one of the pipingdiameters is approximately ½ inch, with air pressure generated atapproximately 2 to approximately 6 bar, and the abrasive particulatesper shot are approximately 25 to approximately 80 grams.
 3. The methodof claim 1, wherein at least one of the piping diameters isapproximately ¾ of an inch, with air pressure generated at approximately2 to approximately 6 bar, and the abrasive particulates per shot areapproximately 40 to approximately 120 grams.
 4. The method of claim 1,wherein at least one of the piping diameters is approximately 1 inch,with air pressure generated at approximately 2 to approximately 6 bar,and the abrasive particulates per shot are approximately 60 toapproximately 160 grams.
 5. The method of claim 1, wherein at least oneof the piping diameters is approximately 1½ of an inch, with airpressure generated at approximately 3 to approximately 7 bar, and theabrasive particulates per shot are approximately 75 to approximately 200grams.
 6. The method of claim 1, wherein at least one of the pipingdiameters is approximately 1¾ of an inch, with air pressure generated atapproximately 3 to approximately 7 bar, and the abrasive particulatesper shot are approximately 75 to approximately 200 grams.